Temperature controlling device for aerosol drug delivery

ABSTRACT

A portable air temperature controlling device useful for warming air surrounding an aerosolized drug formulation. Warming the air of an aerosol makes it possible to reduce the diameter of aerosol particles produced by an aerosol generation device. Additionally, warming the air forces the diameter of the aerosol particles to be in the range required for systemic drug delivery independent of ambient conditions. Smaller particles can be more precisely targeted to different areas of the respiratory tract.

CROSS-REFERENCES

This application is a continuation-in-part application of U.S. Ser. No.09/690,242 filed Oct. 16, 2000 (issued Jul. 24, 2001 as U.S. Pat. No.6,263,872) which is a continuation of U.S. application Ser. No.09/107,306 filed Jun. 30, 1998 (issued Oct. 17, 2000 as U.S. Pat. No.6,131,570) which is a continuation-in-part of U.S. application Ser. No.08/752,946 filed Nov. 21, 1996, now issued U.S. Pat. No. 5,906,202 whichapplications and patents are incorporated herein by reference and towhich applications we claim priority under 35 U.S.C. '120.

FIELD OF THE INVENTION

This invention relates generally to portable devices and methods usefulfor optimizing the diameter distribution of a medical aerosol, andreducing the amount of variability arising from variations in ambientconditions. More specifically, this invention relates to portabledevices for controlling the temperature of air to be mixed with aerosolparticles of drugs to be delivered to the lung.

BACKGROUND OF THE INVENTION

There are several known methods for the aerosolized delivery of drugs.In general, the methods include: (1) placing an aqueous formulationwithin a nebulizer device which by various mechanical means causes thedrug formulation to be aerosolized in a continuous stream which isinhaled by the patient; (2) dry powder inhalers which create a finepowder of the drug and aerosolize the powder in a dust form which isinhaled; (3) metered dose inhalers which dissolve or disperse the drugin a low boiling point propellant; and (4) more current devices such asthat disclosed within U.S. Pat. No. 5,660,166 issued Aug. 26, 1997 whichforce aqueous formulations through a nozzle to create an aerosol whichis inhaled by the patient.

In accordance with each of the known methods for aerosolizing a drug itis important to produce an aerosol which has particles within a desireddiameter range, e.g. 0.5 to 12.0 microns and more preferably 1.0 to 3.5microns. In addition to producing small particles it is preferable toproduce particles which are relatively consistent in diameter, i.e.produce an aerosol wherein a large percentage of the particles fallwithin the desired diameter range. In addition, it is desirable toproduce an aerosol which has the property that the key measures ofaerosol quality, such as particle diameter and dose emitted are noteffected by ambient conditions such as temperature and or relativehumidity. With any of the known methods for aerosol delivery of drugsthere are difficulties with respect to making the particles sufficientlysmall. Along with these difficulties there are difficulties with respectto creating particles which are relatively consistent in diameter. Thesedifficulties are particularly acute when attempting to provide forsystemic delivery of an aerosolized drug. Efficient systemic deliveryrequires that the aerosol be delivered deeply into the lung so that thedrug can efficiently reach the air/blood exchange membranes in the lungand migrate into the circulatory system.

Aerosol delivery to the lungs has been used for delivery of medicationfor local therapy (Graeser and Rowe, Journal of Allergy 6:415 1935). Thelarge surface area, thin epithelial layer, and highly vascularizednature of the peripheral lung (Taylor, Adv. Drug Deliv. Rev. 5:37 1990)also make it an attractive site for non-invasive systemic delivery.Unlike other avenues of non-invasive delivery such as trans-dermal,nasal, or buccal, the lung is designed as a portal of entry to thesystemic circulation. However, targeting the peripheral lung requirescareful control of the aerosol particle diameter and velocitydistributions, in order to by pass the exquisitely evolved particlefiltering and clearing functions of the bronchial airways.

Many authors have reported results of experiments or mathematical modelsshowing that micron sized particles are required for delivery to thelungs (c.f. Stahlhofen, Gebhart and Heyder, Am. Ind. Hyg. Assoc. J.41:385 1980, or Ferron, Kreyling and Haider, J. Aerosol Sci. 19:6111987). One example is the model of the Task Group on Lung Dynamics(Morrow et. al. Health Physics 12:173 1966). As FIG. 1 shows, under theassumptions of this model, particles of diameter less than ˜3.5 μm arerequired to avoid the oropharynx and bronchial airways. FIG. 1 mightsuggest that the maximum efficiency of deposition of drugs delivered tothe pulmonary region of the lung is limited to ˜60%. However, as can beseen in FIG. 2, efficiencies approaching 100% can be achieved byallowing the particles to settle gravitationally during a ten secondbreath hold (Byron, J. Pharm. Sci. 75:433 1986).

It has been demonstrated that ambient conditions can strongly effect theamount of aerosol particles less than 3.5 μm emitted from aerosolgeneration device. One example is the work of Phipps and Gonda (Chest97:1327-1332, 1990) showing that the amount of aerosol less than 3.5 μmdelivered by an aerosol drug delivery device changed from 33% to 73%when the relative humidity changed from 100% to 70%. Similar work with adry powder (Hickey et al J. Pharm. Sci. 79, 1009-1011) demonstrated achange in the amount of aerosol less than 3.5 μm from 9% to 42% when theambient relative humidity changed from 97% to 20%. These data aretabulated in Table 1. TABLE 1 Effect of RH on Particle DiameterDistribution Aerosol T, ° C. R.H., % % <3.5 μm Isotonic Saline¹, HudsonUp-Draft 23-24° 100% 33% Isotonic Saline¹, Hudson Up-Draft 23-24° 65-75%73% Fluorescein Powder² 37 ± 0.1° 97 ± 1%  9% Fluorescein Powder² 37 ±0.1° 20 ± 5% 42%¹Phipps and Gonda, 1990²Hickey et al 1990

A device useful for controlling the temperature of the air surroundingan aerosolized drug formulation is provided in U.S. Pat. No. 6,131,570,which issued on Oct. 17, 2000. An element is preheated prior toaerosolizing the drug formulation. After preheating has beenaccomplished, the drug formulation is aerosolized substantiallycontemporaneously with the control of air flow through a space in whichthe preheated element is contained, whereby heated air mixes with theaerosolized drug formulation, thereby evaporating liquid carrier fromthe aerosol particles to obtain smaller particles to be delivered to thelungs of the patient.

Since devices of this type are designed to be portable, primary goalsinclude making the heating element as efficient as possible forperforming the functions of rapidly heating up and storing energy duringthe preheat stage, as well as rapidly releasing heat to the air as itflows by the heating element to be delivered to the aerosolized drug.Efficient storing and releasing of heat energy are basicallycontradictory in nature, however, and these goals remain a problem to beaddressed, since increasing the efficiency of these features allows areduction in the size and weight of the power source which mustnecessarily be included in a portable device.

Many pharmaceutical compounds of a wide range of molecular weights arepotential candidates for systemic delivery via the lung. Small moleculesanalgesics such as morphine or fentanyl could be delivered to painpatients, e.g. cancer or post-operative patients. Morphine hasdemonstrated bioavailability when delivered via the lung (S. J. Farr, J.A. Schuster, P. M. Lloyd, L. J. Lloyd, J. K. Okikawa, and R. M.Rubsamen. In R. N. Dalby, P. R. Byron, and S. J. Farr (eds.),Respiratory Drug Delivery V, Interpharm Press, Inc., Buffalo Grove,1996, 175-185).

Potent peptide hormones are available for a variety of therapeuticindications. Leuprolide, for example, is a GnRH super-agonist useful inthe treatment of endometriosis and prostate cancer. Leuprolide also haspotential applications in the field of breast cancer management and thetreatment of precocious puberty. Calcitonin enhances metabolism and maybe a useful therapeutic agent for the management of osteoporosis, acommon complication of aging.

To treat conditions or diseases of the endocrine system, pharmaceuticalformulations containing potent peptide hormones are typicallyadministered by injection. Because the stomach presents a highly acidicenvironment, oral preparations of peptides are unstable and readilyhydrolyzed in the gastric environment. Currently, there are no oralpreparations of therapeutic peptide agents commercially available.

Both calcitonin and leuprolide can be administered nasally. (See Rizzatoet al., Curr. Ther. Res. 45:761-766, 1989.) Both drugs achieve bloodlevels when introduced into the nose from an aerosol spray device.However, experiments by Adjei et al. have shown that the bioavailabilityof leuprolide when administered intranasally is relatively low. However,an increase in the bioavailability of leuprolide can be obtained byadministering the drug into the lung. Intrapulmonary administration ofleuprolide has been shown to be an effective means of non-invasiveadministration of this drug (Adjei and Garren, Pharmaceutical Research,Vol. 7, No. 6, 1990).

Intrapulmonary administration of drugs has the advantage of utilizingthe large surface area available for drug absorption presented by lungtissue. This large surface area means that a relatively small amount ofdrug comes into contact with each square centimeter of lung parenchyma.This fact reduces the potential for tissue irritation by the drug anddrug formulation. Local irritation has been seen with nasal delivery ofinsulin and has been a problem for commercialization of nasalpreparations of that drug. It is a problem with peptide hormones thatthey are very potent with effects that are not immediately manifested.For example, therapy with leuprolide for prostate cancer does nottypically produce any acute clinical effects. Similarly, prophylaxisagainst osteoporosis with calcitonin will not produce any acute symptomsdiscernible to the patient. Therefore, administration of each dose ofthese drugs must be reliable and reproducible.

SUMMARY OF THE INVENTION

A portable, self-contained device useful for controlling the temperatureof the air surrounding an aerosolized drug formulation is provided, aswell as methods for more efficiently transferring heat energy to airwhich is thereby warmed and applied to the drug formulation. A method ofdissipating power to store heat, and then releasing the stored heat towarm a bolus of air, and a device for carrying out such method areprovided. Such a method includes supplying power from a portable powersource to a heating element; storing heat in the heating element aspower is supplied from the portable power source; determining when theheating element achieves a predetermined operating temperature; andflowing air over the heating element after the heating element hasachieved the predetermined operating temperature, to release heat to theflowing air, whereby the thermal time constant of the device may begreater than about 10 seconds in still air, preferably greater thanabout 15 seconds, more preferably greater than about 20 seconds, stillmore preferably greater than about 30 seconds and most preferablygreater than about 40 seconds, and the thermal constant of the devicefor releasing heat to the flowing air is less than about 15 seconds,more preferably less than about 7 seconds, even more preferably lessthan about 5 seconds.

During the preheat phase, as heat is stored in the heating element, itis noted that energy may be distributed within the heating element. Forexample, a primary element may be heated, and some or all of the heatgenerated may be distributed to a secondary element for storage.

The flowing air may be driven by inhalation by a user on a channelfluidly connected with the heating element. However, it would also bepossible to construct a heating device employing some other driver forpassing air over the heating element (such as an electric fan, forexample) to warm the air in much the same manner that the inhaled air iswarmed. The patient could subsequently inhale the evaporated drug from aholding chamber into which the fan blows the warmed air (whichevaporates the drug and carries it to the holding chamber). The portablepower source may comprise at least one battery cell with or without atleast one capacitor, for example.

The present invention includes modifications of a heating device, andparticularly heating element to increase the thermal time constant ofthe heating device in still air. Such modifications may include coatingthe thermal element with gold; providing a shield around the heatingelement and, optionally, one or more shield closing elements, to reflectradiant heat, mitigate losses from the heating element to the channeldue to free convection, and to absorb some heat that would otherwisehave been lost from the heating element during storing of heat, whereinthe shield (and optionally, shield closing elements) function(s) as asecondary heat storage element that can subsequently release heat forwarming the moving air; coating the shield and or shield closingelements with gold; and combinations thereof.

Modifications of a heating device to optimize the thermal time constantof the heating device in moving air are also disclosed. Suchcharacteristics may include configuring one or more passive elements toabsorb heat from and release heat to the moving air. The heating elementmay comprise a shape that enhances heat transfer in moving air.

Hand-held, portable air temperature controlling devices are disclosedwhich comprise a heating element adapted to receive energy from aself-contained, portable power source and store the energy as heatduring a preheat operation; and a housing surrounding the heatingelement and defining an air flow path through which air flows over theheating element to transfer heat to the air during an air warmingoperation; wherein a thermal time constant of the heating device instill air during the preheat operation is greater than about 15 secondsand a thermal time constant of the heating device in moving air duringthe warming operation is less than about 15 seconds.

A shield may be provided to substantially surround the heating element,while remaining open at opposite ends to allow air to pass therethrough.Optionally, a shield closing element may be provided in one or each openend to further shield and surround the heating element during preheat,while allowing air flow therethrough during an air warming operation.

A passive element may be provided downstream of the heating element,wherein the passive element conditions a heat pulse generated when airflows over the heating element to transfer heat to the air during theair warming operation.

An air temperature controlling device is further disclosed as comprisinga self-contained, portable power source adapted to connect with theheating (or thermal) element to supply power thereto.

In one example, a hand-held, portable air temperature controlling devicecomprises a heating element adapted to receive energy from aself-contained, portable power source and store the energy as heatduring a preheat operation; and a housing surrounding the heatingelement and defining an air flow path through which air flows over theheating element to transfer heat to the air during an air warmingoperation; wherein the heating element comprises an electricallyresistive ribbon having a thermal time constant in still air during thepreheat operation which is greater than about 15 seconds and a thermaltime constant in moving air during the warming operation which is lessthan about 15 seconds.

The resistive ribbon may be constructed of two banks, with each bankbeing configured into a series of narrow channels.

Further, a shield may be provided to substantially surround theresistive ribbon, while having open opposite ends to allow air to passtherethrough.

Still further, a shield closing element, such as a mesh element may befitted in one or both of the open opposite ends of the shield.

The invention increases the number and types of pharmaceuticalformulations which can be administered efficiently and reproducibly byinhalation. More particularly, the invention makes it possible to inhaleformulations which are intended for systemic delivery, includingpeptides such as insulin and analogs of insulin (e.g., insulin lispro).This is done by increasing the reproducibility of dosing by adjustingparticle diameter to a consistent level in different surroundinghumidities. Further, particular areas of the lung are targeted by (1)including aerosolized formulation in precisely determined volumes ofair, (2) warming air surrounding the aerosolized formulation so as toevaporate carrier and reduce the particle diameter and/or to preventwater vapor in the air from condensing on particles, (3) excludingaerosolized formulation from other volumes of air delivered to the lungin order to correctly position an aerosol. Further, the heating meanscan be used with any type of means of generating an aerosol. Morespecifically, the heating means can be used with a nebulizer, a drypowder inhaler or metered dose inhaler. However, the major benefits ofthe invention are obtained when used with a device which createsaerosolized particles by moving liquid (aqueous or ethanolic)formulations through small holes to create particles (see U.S. Pat. No.5,718,222 issued Feb. 17, 1998). All types of nebulizers benefit fromthe invention by reducing variable effects caused by the environment,e.g., changes in humidity.

The amount of energy added can be adjusted depending on factors such asthe desired particle diameter, the amount of the carrier to beevaporated, the water vapor content (humidity) and temperature of thesurrounding air, the composition of the carrier, and the region of thelung targeted.

To obtain reproducible, efficient systemic delivery it is desirable toget the aerosolized formulation deeply into the lung. This requires thedelivery of the formulation in aerosol particles of diameter less thanapproximately 3.5 μm. Direct generation of particles in this diameterrange can be difficult, due to the large ratio of surface area to volumeof these small particles. Energy may be added in an amount sufficient toevaporate all or substantially all of the carrier from an aqueousaerosol and thereby provide particles of dry powdered drug or highlyconcentrated drug formulation to a patient which particles are (1)uniform in diameter regardless of the ambient humidity and temperature(2) preferably produced from a liquid formulation, and (3) smaller dueto the evaporation of the carrier.

A primary object of the invention is to provide an air temperaturecontrolling device comprised of a receptacle for holding aself-contained power source such as electric power cells forming abattery, a channel comprising an air flow path which includes an openinginto which air can be inhaled and a second opening into which air isdelivered and aerosol is generated, a heating element connected to theelectrical contacts of the receptacle and positioned in a manner suchthat air flowing by the heating element flows through the channel,wherein the device is a hand-held, self-contained device having a totalweight of one kilogram or less.

An important advantage of the invention is that the heating device canheat a sufficient amount of air so as to evaporate a sufficient amountof carrier on aerosolized particles to make the particles consistent indiameter and sufficiently small as to improve the repeatability andefficiency of drug delivery.

It is an object of this invention to provide a portable air temperaturecontrolling device able to warm the air which will interact withparticles of an aerosolized drug formulation.

It is a further object of the invention to provide a drug deliverydevice containing such a heating element which is heated by a portable,self-contained energy source.

It is a further object of the invention to provide methods ofadministering aerosolized drug formulations in which the air,interacting with or to interact with the aerosolized formulation, iswarmed using a portable air temperature controlling device.

An advantage of the present invention is that it can be used forambulatory patients.

Another object of the invention is that it makes it possible to adjustparticle diameter by adding energy to the air surrounding the particlesin an amount sufficient to evaporate carrier and reduce total particlediameter.

Another object of the invention is that it reduces or eliminates thevariability in particle diameter due to variations in ambient relativehumidity and temperature by ensuring that the delivered particles are inthe range of 1-3.5 μm independent of ambient conditions. This object ofthe invention can apply equally well to aerosol generation devices thatgenerate aerosols of liquid solutions of drug, liquid suspensions ofdrug, or dry powders of drug.

Another object is to provide a device for the delivery of aerosols whichmeasures ambient humidity via a solid state hygrometer, and/or measuresambient temperature via a temperature sensor.

A feature of the invention is that drug can be dispersed or dissolved ina liquid carrier such as water and dispersed to a patient as dry orsubstantially dry particles.

These and other objects, advantages and features of the presentinvention will become apparent to those skilled in the art upon readingthis disclosure in combination with drawings wherein like numerals referto like components throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graphic model showing the fraction of particles that depositin the pulmonary, tracheobronchial, and oro-pharyngeal compartments, asa function of particle diameter;

FIG. 2 is a graphic model similar to FIG. 1, showing the effect of abreath hold maneuver on lung deposition;

FIG. 3 is a schematic view of an embodiment of an air temperaturecontrolling device of the invention;

FIG. 4 is a schematic view of an embodiment of an aerosol deliverydevice of the invention;

FIG. 5 is an end view of a configuration of a heating element accordingto the present invention;

FIG. 6 is a plan view of an electrically resistive ribbon used in makinga heating element according to the present invention;

FIG. 7A is a schematic showing channels of one bank of a heating elementsubstantially aligned with respect to the other bank;

FIG. 7B is a schematic showing channels of one bank of a heating elementsubstantially non-aligned with respect to the other bank;

FIG. 8 is a view of a heating element mounted in a channel according tothe present invention, with the view of the channel being cut away;

FIG. 9 is an end view of a heating element mounted in a channelaccording to the present invention;

FIG. 10 is an end view of a heating element mounted in a channel andshowing a mesh element fitted at the end of the channel;

FIG. 11 shows an arrangement employing a passive element to lengthen thetime constant in moving air of the heating device;

FIG. 12 is a graph plotting the density (mg/liter) of water vapor in airversus temperature;

FIG. 13 is a graph plotting the density (mg/liter) of ethanol vapor inair versus temperature;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before the present air temperature controlling device, method ofaerosolizing formulations and devices and formulations used inconnection with such are described, it is to be understood that thisinvention is not limited to the particular embodiments described, assuch heating elements, methods, devices, packages, containers andformulations may, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularembodiments only, and is not intended to limit the scope of the presentinvention which will be limited only by the appended claims.

It must be noted that as used herein and in the appended claims, thesingular forms “a,” “an,” and “the” include plural referents unless thecontext clearly dictates otherwise. Thus, for example, reference to “aformulation” includes mixtures of different formulations, reference to“an aerosolized compound” includes a plurality of such compounds, andreference to “the method of treatment” includes reference to equivalentsteps and methods known to those skilled in the art, and so forth.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Although any methods andmaterials similar or equivalent to those described herein can be used inthe practice or testing of the present invention, the preferred methodsand materials are now described. All publications mentioned herein areincorporated herein by reference to disclose and describe the specificmethods and/or materials in connection with which the publications arecited.

The publications discussed herein are provided solely for theirdisclosure prior to the filing date of the present application. Nothingherein is to be construed as an admission that the present invention isnot entitled to antedate such publication by virtue of prior invention.Further, the dates of publication provided may be different from theactual publication dates which may need to be independently confirmed.

Definitions

The terms “portable air temperature controlling device”, “airtemperature controller” and the like refer to a self-contained devicecomprising a heating element which can be positioned in an aerosoldelivery device in a manner such that air of an aerosol created by thedevice is warmed when contacting the heating element. The devicepreferably includes a receptacle for a power source for the heating ofthe heating element, and a control circuit to monitor and control thetemperature of the heating element.

The term “receptacle” refers to a location in a portable drug deliverydevice for connecting a portable power source which power source ispreferably two or more electric cells, i.e. a battery. The airtemperature controlling device is preferably an integral part of anaerosol delivery device which together (with the power source) weighless than 1.5 kg; more preferably, less than 0.75 kg. The receptacle mayconsist of an attachment point essentially outside of the device, orpreferably an enclosed volume with a door that contains the power sourceinside the device. The receptacle preferably contains a method ofconnecting and disconnecting the means of transmitting power from thepower source to the air temperature controlling device, such aselectrical contacts.

The term “portable power source” refers to any source capable ofgenerating power which can be transferred to the heating element in theportable air temperature controlling device, and preferably is a sourceof electrical energy, more preferably stored in a chemical cell which isan electric cell (two or more electric cells combined forms a battery)with or without the use of one or more capacitors in conjunctiontherewith. In a preferred embodiment the power source is one or moreelectrical cells, (i.e. a battery) which is/are sufficiently small suchthat when loaded into the device the device remains easily portable,e.g., AA size, C size or D size or smaller. Chemical reactions(especially the catalytic combustion of butane), hand-powered generatorsor friction devices could also be used.

The term “heating element” refers to any element capable of convertingpower provided by a portable power source into heat, storing the heatand then subsequently releasing it to the surrounding air. However,during storage, the heat energy may be distributed within the heatingelement. For example, a first element may be heated and the heat energygenerated may be transferred into a secondary element for storage.Heating elements can be in the form of an electrically resistivematerial, such as one or more wires, stamped and/or folded sheets,ribbons or mesh, for example. The heating element is generally made ofmetal, although the present invention is not limited thereto, as heatingelements made from other non-metallic materials exhibiting the desiredcharacteristics as described herein may also be used. If the source ofpower is an electric cell or group of electric cells (a battery), theheating element must be designed so that its operation is consistentwith a battery which is portable (size and weight are small) and canprovide enough energy over a short period of time (e.g., one minute orless) to heat the heating element so that the air temperature controllerholds enough energy to warm the air into which the aerosol is generatedsufficiently to evaporate the desired amount of carrier away from theparticles.

The terms “preheat” and “preheating” refer to the period of time and aprocess during which the heating element is heated from an initialtemperature up to an operating temperature.

The terms “air warming”, “air warming operation” and “air warmingperiod” refer to the period of time commencing on or after achieving theoperating temperature and after preheat, and during which stored heat istransferred from the heating device to air flowing through the channelthat houses the heating element and any other components involved duringthe preheat.

The term “operating temperature” refers to a predetermined temperatureat which time energy stored by the heating element during preheat may bereleased to air flowing into a channel of a device according to thepresent invention. The operating temperature, although predetermined,may vary according to the substance to be delivered by the device, theambient temperature, the ambient humidity, and among other factors, asdescribed in more detail below.

The term “thermal time constant” is a measure of the response time ofcooling of the temperature controlling device and is a measure of thetime it takes the heating device to cool from the operating temperatureto a temperature equal to the sum of the initial temperature (e.g.,usually ambient temperature) and 1/e of the difference between theoperating temperature and the initial temperature, in the absence of anyadditional energy input thereto.

The “thermal time constant in moving air” refers to the thermal timeconstant of the heating device as air flows over the heating element asa result of inhalation by a patient or other operational driver of theairflow.

The term “thermal time constant in still air” refers to the thermal timeconstant in the absence of air flow, and where the air surrounding theheating element is substantially motionless.

The terms “hormone,” “hormone drug,” “pharmaceutically active hormoneformulation,” “peptide used in endocrine therapy,” “peptide hormonedrug,” “peptide drug” and the like are used interchangeably herein. Ahormone drug as described herein is a peptide drug which has beenprepared in a pharmaceutically effective formulation and is useful inendocrine therapy. Specifically, a peptide drug of the type describedherein is useful for exogenously modifying the behavior of a patient'sendocrine system. Peptide drugs which are used in the present inventioninclude those listed in Table2, it being noted that these peptidespreferably contain less than 50, more preferably less than 27, aminoacids. Drugs of smaller size are preferred. Particularly useful peptidedrugs for use with the invention include leuprolide, calcitonin, andnafarelin. The devices and methods disclosed herein can be used in thecreation of an aerosol for inhalation into the lungs using anypharmaceutically active peptide. Examples of useful peptides include:TABLE 2 Insulin (e.g. human recombinant) Insulin analogs (e.g. insulinlispro) Interferon-alpha Interferon-gamma HPTH (human parathyroidhormone) GCSF (granulocyte colony stimulating factor) GMCSF (granulocytemacrophage colony stimulating factor) Atrual natriuretic factorAngiotensin inhibitor Renen inhibitor Somatomedin FSH (folliclestimulating hormone) Tissue growth factors (TGF's) Endothelial growthfactors HGF (hepatocyte growth factor) Amylin Factor VIII VasopressinIIB/IIIA peptide antagonists

The invention is intended to cover such pharmaceutically activepeptides, which are synthetic, naturally occurring, glycosylated,unglycosylated, pegylated forms and biologically active analogs thereof.The invention can be applied to the aerosolized delivery of insulin andinsulin analogs, particularly any monomeric insulin (e.g. insulinlispro).

The terms “drug”, “pharmaceutically active drug”, and “active drug” andthe like are used interchangeably herein to refer to any chemicalcompound which, when provided to a mammal, preferably a human, providesa therapeutic effect. Preferred drugs are peptide hormones, proteinssuch as erythropoietin, peptides and the like including insulin andinsulin analogs such as insulin lispro, small molecule drugs includingmorphine, fentanyl, and the like, i.e. drugs which are commonly used andwhich are conventionally delivered by injection.

The term “treatment” is used here to cover any treatment of any diseaseor condition in a mammal, particularly a human, and includes:

(a) preventing the disease or condition from occurring in a subjectwhich may be predisposed to the disease but has not yet been diagnosedas having it;

(b) inhibiting the disease or condition, i.e. arresting its development;and/or

(c) relieving the disease or condition, i.e. causing regression of thedisease and/or its symptoms.

The term “dosing event” shall be interpreted to mean the administrationof a drug to a patient in need thereof by the intrapulmonary route ofadministration which event may encompass one or more releases of drugformulation from a drug dispensing device over a period of time of 15minutes or less, preferably 10 minutes or less, and more preferably 5minutes or less, during which period an inhalation or multipleinhalations are made by the patient and a dose of drug is released andinhaled. A dosing event shall involve the administration of drug to thepatient in an amount of about 1 μg to about 10 mg. The dosing event mayinvolve the release of from about 1 μg to about 100 mg of drug from thedevice.

The term “bulk flow rate” shall mean the average velocity at which airmoves through a channel considering that the flow rate is at a maximumin the center of the channel and at a minimum at the inner surface ofthe channel.

The term “carrier” shall mean any non-active compounds present in theformulation. The carrier is preferably a liquid, flowable,pharmaceutically acceptable excipient material which thepharmaceutically active drug is suspended in or more preferablydissolved in. Useful carriers do not adversely interact with the drug orpackaging and have properties which allow for the formation of aerosolparticles preferably having a diameter in the range of 0.5 to 15microns. The particles may be formed when a formulation comprising thecarrier and drug is forced through pores having a diameter of 0.25 to3.0 microns. Preferred carriers include water, ethanol and mixturesthereof. Other carriers can be used provided that they can be formulatedto create a suitable aerosol and do not adversely effect the drug orhuman lung tissue. The term carrier includes excipient materials whichare used with formulation for nebulizers, any powder inhalers andmetered dose inhalers or devices of the type described in U.S. Pat. No.5,709,202.

The term “inspiratory volume” shall mean a measured, calculated and/ordetermined volume of air passing a given point into the lungs of apatient assuming atmospheric pressure ±5% and a temperature in the rangeof 10 C to 40 C.

The terms “formulation” and “liquid formulation” and the like are usedherein to describe any pharmaceutically active drug by itself or with apharmaceutically acceptable carrier. A formulation could be a powder,that may have previously been spray dried, lyophilized, milled, or thelike, and may contain a large amount of inactive ingredients such aslactose or mannitol. The formulation is preferably in flowable liquidform having a viscosity and other characteristics such that theformulation can be aerosolized into particles which are inhaled into thelungs of a patient after the formulation is aerosolized, e.g. by beingmoved through a porous membrane. Such formulations are preferablysolutions, e.g. aqueous solutions, ethanolic solutions,aqueous/ethanolic solutions, saline solutions, microcrystallinesuspensions and colloidal suspensions. Formulations can be solutions orsuspensions of drug in a low boiling point propellant or even drypowders. Dry powders tend to absorb moisture and the invention decreasesthe moisture content and makes it possible to deliver particles ofpowder which have a consistent diameter even when the surroundinghumidity is variable.

The term “substantially dry” shall mean that particles of formulationincluding an amount of carrier (e.g. water or ethanol) which iscomparable to (in weight) or less than the amount of drug in theparticle. Preferably such particles consist essentially of only drugwith no free carrier e.g., no free water, ethanol or other liquid.

The terms “aerosol,” “particles,” “aerosol particles,” “aerosolizedformulation” and the like are used interchangeably herein and shall meanparticles of formulation comprised of pharmaceutically active drug andcarrier which are formed for aerosol delivery, e.g. upon forcing theformulation through a nozzle which nozzle is preferably in the form of aflexible porous membrane or generated using a jet or ultrasonicnebulizer. Preferably, the particles have a diameter in the range of 0.5micron to about 12 microns (more preferably 1-3.5 microns).

The terms “particle diameter” and “diameter” are used when referring tothe diameter of an aerosol particle and are defined as the “aerodynamicdiameter”. The “aerodynamic diameter” is the physical diameter of asphere of unit density (1 gm/cm³) that has the same terminalsedimentation velocity in air under normal atmospheric conditions as theparticle in question. This is pointed out in that it is difficult toaccurately measure the physical diameter of small particles usingcurrent technology and because the shape may be continually changing. Inaddition, the deposition of aerosol particles in the bronchial airwaysof a human subject is described by a Stokes impaction mechanism which ischaracterized by a particle's aerodynamic diameter. Thus, the diameterof one particle will be said to have the same diameter as anotherparticle of the same or different material if the two particles have thesame terminal sedimentation velocity in air under the same conditions.

The terms “ambient conditions,” “ambient temperature,” “ambient relativehumidity” refer to the conditions of the air surrounding the patient andaerosol generation device, prior to this air being entrained into thedevice and being conditioned by the temperature controller.

The term “aerosol generation device” refers to any device for forming anaerosol for delivery to a human. These devices include but are notlimited to systems that generate aerosols from liquid formulations, suchas jet or ultrasonic nebulizers, spinning top generators, devices usingan orifice or an array of orifices to form an aerosol (driven by aoscillation mechanism or not), and devices for the delivery of drypowder aerosols. Different types of aerosol delivery devices can utilizethe temperature controller components described herein.

The term “drug delivery device” refers to a self contained portabledevice for the delivery of medication by way of inhalation. The drugdelivery device preferably comprises a temperature controller component.

The term “temperature sensor” refers to an electrical component that hassome measurable, repeatable property that can be used to determine thetemperature of the component, and thus the temperature of some othersubstance which the sensor is in thermal contact with, such as a heatingelement or the surrounding air. The temperature sensor can be athermocouple, a diode, or preferably a resistance device such as athermistor or RTD.

The term “temperature coefficient of resistance” refers to the amount ofchange of the resistance of an electrical component. The temperature ofa component can be measured by measuring its resistance, assuming it hasa sufficiently large temperature coefficient of resistance over therange of temperatures of interest, the resistance changes monotonically,and its resistance as a function of temperature has previously beendetermined. The component could be a heating element, or a temperaturesensor. If the component is a heating element, the preferred alloy isnickel-chromium, or similar alloy.

Device in General

An air temperature controlling device for use in conjunction with anaerosol generation device for the delivery of drugs via aerosol to thelung is disclosed. The device has a self-contained, portable powersource included (electric cells which form a battery, or a combustiblefuel together with a catalyst material, for example). The drug deliverydevice may include a receptacle for the self-contained power source. Thereceptacle may hold an electrical cell or cells in the receptacle inwhich case the receptacle will include electrical contacts. Thetemperature controlling device preferably comprises a channel whichforms an air flow path having a first opening into which ambient air canbe drawn and a second opening from which conditioned air can bedelivered to the aerosol generation device, where the driving force forthe air flow is preferably the patient's inhalation. The temperaturecontrolling device preferably comprises a heating element which isconnected to the contacts of the receptacle for the self-contained powersource. In the preferred embodiment, the power source is a battery andthe contacts are electrical contacts. However, the power source may be acontainer of a combustible fuel such as butane or propane, for example,in which case the contacts would be a means of connecting the powersource to the means of delivering the combustible fuel to the heatingelement.

The heating element is positioned in a manner such that air flowingthrough the air flow path contacts the heating element and is warmed. Inthe case of a liquid formulation, the air is warmed to the extent thatit can hold all or part of the carrier in the particles after it hasbeen cooled by the process of carrier evaporation (see FIGS. 12 and 13),under all ambient conditions expected to be encountered over thelifetime of the device. In the case of a dry powder inhaler, the air iswarmed to the extent that particle growth is inhibited at all ambientconditions expected to be encountered over the lifetime of the device.Preferably, the air is warmed in an amount such as to result in theevaporation of 50% or more of any liquid carrier and more preferablywarmed to the extent to evaporate substantially all the compound liquidcarrier leaving the particles dry, i.e. leaving the particles in a formwhere any liquid carrier such as water and/or ethanol which is notcomplexed with or bound to the solute has been evaporated away. Thedevice is a hand-held, self-contained device which has a total weight of1 kilogram or less in its loaded form.

The aerosol generation device to be combined with the present inventionis preferably loaded with a disposable drug container of the typedisclosed within U.S. Pat. No. 5,497,763 issued Mar. 12, 1996—see alsoU.S. Pat. No. 5,544,646 issued Aug. 13, 1996, U.S. Pat. No. 5,660,166issued Aug. 26, 1997, U.S. Pat. No. 6,131,570, issued Oct. 17, 2000, andU.S. Pat. No. 5,718,222 issued Feb. 17, 1998, all of which areincorporated herein by reference to disclose an aerosol generationdevice and a disposable container for containing a drug for aerosolizeddelivery.

Different embodiments of the air temperature controlling device of thepresent invention may contain a variety of different power sourcesprovided the power source is self-contained allowing the device to behand held and portable. The power source may be an electric cell or aplurality of electric cells, i.e. a battery. Typically, a receptacleholds a battery securely in place and has electrical metal contacts tocontact a positive and negative end of an electric cell or battery,although it would be possible to mount one or more batteries to thedevice and electrically connecting the batteries to a heating elementwithout using a receptable. Different types of batteries can be usedincluding rechargeable batteries. It is preferable to use standard sizecells, more preferably AA (or similar) size cells. Specifically, thepresent invention has been developed so that it is very light weight andportable and can provide the necessary warming by power received from afew AA size electric cells, or less. However, the invention is intendedto encompass portable devices which include somewhat larger electriccells, e.g. D size electric cells or smaller.

The power source is brought into contact with electrical contacts (inthe battery powered embodiments) on the receptacle, or otherwiseelectrically connected to the drug delivery device, thereby powering thedrug delivery device. The electrical contacts of the receptacle lead tothe heating element which is the most important aspect of the presentinvention and to other components of the device which require power.

The utility of the invention can be heightened by improving theefficiency of the air temperature controlling device, thus minimizingthe number of batteries (and thus the size and weight of the drugdelivery device), and maximizing the number of doses delivered beforethe power source needs to be replaced or recharged. The efficiency ofthe air temperature controller can be increased by insulating the wallsof the air path, thus minimizing the amount of heat lost during thepreheat and storage phases of the cycle. Additionally, a valving meanscan be used to only deliver conditioned air during the period of aerosolgeneration, and deliver ambient air during the parts of an inhalationprior to and following aerosol generation, thus minimizing the amount ofpreheating of the heating element required, and saving heat in theheating element for subsequent inhalations.

The heating element may take a variety of different forms. This form isone key feature in the design of an efficient heating mechanism thatwill minimize heat losses during preheating (i.e., efficiently storeheat), but will maximize the release of heat to the air during an airwarming operation. Although the functions of storing and releasing heatare fundamentally contradictory, the present inventors have developeddistinct approaches to improving the efficiency of each of theserespective functions.

The present invention provides arrangements which emphasize the dominantand distinct heat transfer mechanisms for preheating/storing of heat andreleasing of heat at the particular times during which each function isbeing performed. More specifically, arrangements are provided which aredesigned to substantially eliminate or minimize convective and radiativeheat transfer during preheating, while enhancing or maximizing theability to transfer heat convectively as the air passes over the heatingelement. These arrangements provide systems in which the heating elementis characterized by a relatively long (i.e., greater than 15 seconds)thermal time constant during preheating, but is characterized by a muchshorter (i.e., less than 15 seconds) thermal time constant duringrelease of the heat to the air during an air warming operation. A largeratio of the preheat thermal time constant (i.e., thermal constant instill air) to heat release thermal time constant (i.e., thermal constantin moving air) is a critical feature for a portable device of the typedescribed herein. For example, in a battery embodiment, the amount ofpower required to heat the air directly from the batteries duringaerosol formation typically far exceeds the amount of power that aportable battery pack can supply.

A heating element according to the present invention may be anelectrically resistive element which, when electrically connected to abattery power source will store heat upon the dissipation of power fromthe battery source to the resistive element, and will subsequentlyrelease the stored heat to an air stream driven by inhalation by apatient using a device connected to the heating element. An electricallyresistive element may take the form of one or more wires, stamped and/orfolded sheets, ribbons, foams, meshes, or other geometry adapted to meetthe thermal time constant requirements set forth above. The electricallyresistive element may be formed from an alloy containing some or all ofthe following components: nickel, chromium, iron and copper; from puremetals or from other known electrically resistive materials capable ofperforming to meet the required thermal time constant characteristics. Apreferred heating element is in the form of a metallic ribbon thatprovides a large surface area to mass ratio, most preferably a nichromeribbon Alternatively, the heating element may be formed of metallicfoam, such as nichrome foam, for example; electrically conductive mesh;metallic or other conducting wires that meet the performance describedherein; gold coated wire or wires; gold coated ribbon, foam, mesh orshim stock; for example.

The composition and physical structure of the heating element must becarefully designed in order to provide a heating element which canquickly store energy in the form of heat and thereafter quickly releasethat stored heat energy to the surrounding air. In addition, the heatingelement must be such that it can perform the heat storage and releasetasks when being powered by a small power source such as a few AAelectric cells.

The heating element must be designed so as to provide energy in therange of about 50 to 400 joules, most preferably about 250 joules(although this value will vary depending upon the volume of drug to betreated, the amount of carrier present, and the volume of air to beheated, for example) to the surrounding air in a relatively short periodof time, i.e. about 0.5 to 4.0 seconds, more preferably 1-2 seconds. Inorder to produce such a heating element and power source wherein thedevice remains small and portable it has been found that it is notpossible to design the system wherein the energy is provided in realtime (i.e. at the same time as the aerosol is generated) from anelectrical power source, due to the internal impedance of existingbattery technologies. Accordingly, the power source is used to preheatthe heating element which acts as a heat sink before the energy isdelivered. Thus, the concept is similar to the concept of charging acapacitor in order to operate a flash on a camera. In the same mannerthe heat sink or heating element of the invention acts as a “heatcapacitor” and stores energy from the power source until sufficientenergy is stored and then delivers that stored energy to the surroundingair at a rate well beyond that which would be possible with the powersource itself. Alternatively, the power may be stored in one or moreelectrical capacitors, and then delivered to the heating element (orelements) from the capacitor(s) during aerosol generation. State of theart of high capacity, high discharge rate capacitors should be used.When the patient inhales through the device air is drawn over theheating element and energy is transferred to the air, warming the air.The precise amount of air warmed and the amount which the air is warmedto can be changed using different components in the temperaturecontrolling device, or by changing the amount of preheating of theheating element prior to aerosol generation.

Optimum performance can be achieved by limiting the density of theaerosol generated. For example, it is typical to aerosolize a volume offormulation in the range of about 1 microliter to about 100 microlitersper liter of inhaled air. By making the formulation more concentrated,less energy is required per mass of drug delivered in order to evaporateaway the carrier and produce smaller particles. However, when theformulation is more dilute the heat energy added can have a greatereffect on reducing particle diameter. More specifically, since the moredilute solution will contain a larger amount of carrier the temperaturecontrolling device can have a larger effect on reducing the particlediameter.

The invention preferably includes a control circuit to measure andcontrol the temperature of the heating element. This is required tooptimize the amount of preheating when, for example, the batteries arenear the end of their useful lifetime. It could also monitor thetemperature and relative humidity of the ambient air, and vary theamount of preheating accordingly. The control circuit may be an analogcircuit, digital circuit, or hybrid analog/digital circuit, andpreferably includes a microprocessor. The control circuit of theinvention can be designed to add the desired amount of heat depending onthe amount of carrier in the aerosol particles and (1) the density(number of aerosol particles per liter of air) of the generated aerosol(2) the diameter of the particles initially as well as (3) the diameterof the particles desired after the carrier has been evaporated away. Thecontrol of the aerosol generation device may be integrated in the samecircuit, and may, for example, share the microprocessor whichmicroprocessor may be the type disclosed in U.S. Pat. Nos. 5,404,871,5,542,410 and 5,655,516.

The device may include a hygrometer for measuring ambient humidityand/or a temperature sensor for measuring ambient temperature.Information collected by the hygrometer and/or temperature sensor issupplied to the control circuit which determines the amount of energy tobe added to the surrounding air by the heating element. As the humidityincreases additional energy may be necessary in order to evaporatecarrier away from the particles. In the preferred embodiment, theheating element warms the air sufficiently to evaporate essentially allof the carrier over the range of ambient conditions expected in thelifetime of the device, thus obviating the need for relativehumidity/ambient temperature sensor.

In general, when the heating element is in the form of a thin nickelchromium ribbon the heating element has a weight of approximately 0.05to 5 grams, more preferably 0.1 to 4 grams, most preferably 0.2 to 2grams. The heating element has a surface area of about 25 to 55 cm²,more preferably about 30 to 50 cm², and most preferably about 35 to 45cm². The heating element generally is capable of transferring heat toair flowing over it in the amount of about 50 to 400 joules over aperiod of about 0.5 to 4 seconds, more preferably about 1.0 to 2.0seconds. Table 3,which follows, lists acceptable ranges for valuescharacterizing heating devices employing one or more ribbon elements asa heating element. The values for a specific example (Example) are alsolisted. TABLE 3 More most Preferable preferable preferable ComponentProperty range range range Example units Ribbon Mass 0.05-5.0 0.1-4.00.2-2.0 1.25 grams element surf area  25-60 30-55 35-45 39 cm² Thickness0.0005-0.010 0.001-0.006 0.002-0.004 0.0031 in Resistance 0.05-3.00.2-2.0 0.4-1.4 0.8 ohms channel width <.16 <.11 <.06 0.048 in ShieldMass 0.05-4.0 0.1-3.0 0.2-2.0 0.65 grams Thickness 0.0005-0.0200.001-0.010 0.002-0.005 0.0031 in Shield Closing Percent open area  5-6010-50 20-40 30 % Element Mass 0.08-1.0 0.10-.75‘ .15-.50 0.25 gramsSystem time constant in >15 >20 >30 >40 seconds still air time constantin <15 <10 <7 3.5 seconds moving air Distance between <0.240 <0.160<0.080 0.060 in banks of heating elements Distance between <0.250 <0.180<0.12 .055-.110  in heating element and shield heat capacity  0.2-4.35 0.3-2.0 0.4-1.2 1.0 J/° C. Distance between <0.250 <0.180 <0.12 0.065in shield closing element and heating element Distance between <0.250<0.180 <0.12 .050-0.075 in shield and channel

In general the heating element can include an assembly of ribbonelements.

In general, the ribbon element can be formed into grooves or channelswhich channel air flow therethrough during the time of aerosolformation. A convenient way of obtaining such grooves or channels is bycorrugating the full length of the ribbon. The width of the channels inthe formed element are preferably small enough to mitigate heat lossesdue to free convection during the preheat stage.

It is pointed out that the device of the present invention can be usedto, and actually does, improve the efficiency of drug delivery. However,this is a secondary feature. The primary feature is the improvedreproducibility of the emitted dose and particle diameter over the rangeof ambient conditions likely to be encountered while using the device.The air temperature controlling device aids in improving repeatabilityby keeping the delivered aerosol particles inside of a closelycontrolled diameter range.

The methodology of the invention may be carried out using a portable,hand-held, battery-powered device using a microprocessor as disclosed inU.S. Pat. No. 5,404,871, issued Apr. 11, 1995 and U.S. Pat. No.5,450,336, issued Sep. 12, 1995 incorporated herein by reference,although the methodology is not limited to such devices, as thetemperature controller device may be used with other drug deliverydevices, such as those which generate an aerosol by methods other thanextruding a formulation through a porous membrane. The control circuitcan be additionally designed to monitor inhalation flow rate, totalinhaled volume, and other parameters, and commence generation of aerosolat a predefined optimal point during the inhalation. In accordance withthe example system, the drug is included in an aqueous formulation whichis aerosolized by moving the formulation through a porous membrane. Asnoted above, the heating devices and methods of the present inventionare not limited to use with this type of drug delivery device, however,and may be used in combination with other delivery devices and methods.The pre-programmed information is contained within nonvolatile memorywhich can be modified via an external device. In another embodiment,this pre-programmed information is contained within a “read only” memorywhich can be unplugged from the device and replaced with another memoryunit containing different programming information. In yet anotherembodiment, a microprocessor, containing read only memory which in turncontains the pre-programmed information, is plugged into the device. Foreach of these embodiments, changing the programming of the memory devicereadable by a microprocessor will change the behavior of the device bycausing the microprocessor to be programmed in a different manner. Thisis done to accommodate different drugs for different types of treatment.

The drug which is released to the patient may be in a variety ofdifferent forms. For example, the drug may be an aqueous solution ofdrug, i.e., drug dissolved in water and formed into small particles tocreate an aerosol which is delivered to the patient. Alternatively,liquid suspensions or dry powders may be used. Alternatively, the drugmay be in a solution wherein a low-boiling point propellant is used as asolvent.

Some peptide drugs are subject to being degraded more quickly when insolution such as an aqueous solution. Preferably such drugs are packagedin a dry form and mixed with water prior to administration. A dualcompartment container for carrying out such is shown in U.S. Pat. No.5,672,581. Alternately, the drug is kept in the form of a dry powderwhich is intermixed with an airflow in order to provide for delivery ofdrug to the patient.

Regardless of the type of drug or the form of the drug formulation, itis preferable to create aerosol particles having a diameter in the rangeof about 1 to 3.5 microns. By creating particles which have a relativelynarrow range of diameter, it is possible to further increase theefficiency of the drug delivery system and improve the repeatability ofthe dosing. Thus, it is preferable that the particles not only have adiameter in the range of 1.0 to 3.5 microns but that the mean particlediameter be within a narrow range so that 80% or more of the particlesbeing delivered to a patient have a particle diameter which is within50% of the average particle diameter, preferably 25% of the averageparticle diameter. The heating element is particularly useful inreducing particle diameter and in creating an aerosol with uniform sizedparticles.

The amount of drug delivered to the patient will vary greatly dependingon the particular drug being delivered. In accordance with the presentinvention it is possible to deliver a wide range of drugs. For example,drugs delivered could be drugs which have a systemic effect e.g.leuprolide, insulin and analogs thereof including monomeric insulin, ormorphine; or a local effect in the lungs e.g. Activase, albuterol, orsodium cromoglycate. TABLE 4 Useful Peptide Hormone Drugs Amino Compoundacids Somatostatin 6 Oxytocin 9 Desmopressin 9 LHRH 10 Nafarelin 10Leuprolide 11 ACTH analog 17 Secretin 27 Glucagon 29 Calcitonin 32 GHRH40 Growth hormone 191

Having generally described the invention above reference is now made tothe figures in order to more particularly point out and describe theinvention.

FIG. 1 is a graph of deposition fraction versus particle diameter withthe particle diameter being the aerodynamic diameter of a particlehaving a density of 1 gram per square centimeter with the scale beingread in terms of increasing particle diameter in units of μm. Theaerodynamic diameters are plotted versus the deposition fraction in thelungs. For each of the different lines shown on the graph the data isprovided for the deposition fraction in the different areas of the lungand for the total deposition. As can be seen on the graph theoro-pharyngeal deposition which is basically in the back of the throatoccurs for particles which are somewhat large. Specifically, as theparticle size increases to an aerodynamic diameter above 10 μm nearlyall of the particles are deposited in the oro-pharyngeal area. It ispointed out that the graph does not represent actual data but isbelieved to be a fairly accurate representation of what occurs duringintrapulmonary drug delivery particularly where the patient being testedis breathing at a rate of 15 breaths per minute with a 750 ml tidalvolume.

FIG. 2 is similar to FIG. 1 and is a plot of aerodynamic diameter versusfractional deposition. In FIG. 2 the graphs show “p” which is pulmonarydeposition with “bh” breath holding and without breath holding. Similarto FIG. 1, this graph represents theoretical and not actual data. As canbe seen in the graph the breath holding technique does improve theamount of pulmonary deposition, particularly when the particles have anaerodynamic diameter less than 5 μm.

FIGS. 1 and 2 together clearly indicate the importance of the presentinvention. Specifically, the figures indicate that the area of the lungwhich particles deposit in and the percentage of the particles whichdeposit there is substantially effected by the aerodynamic diameter ofthe particles. In that the present invention makes it possible toprovide for consistent aerodynamic particle size the invention providesfor consistent delivery of the particles to particular areas of the lungand therefore repeatable dosing of a patient.

FIG. 3 schematically shows an embodiment of the air temperaturecontroller which employs a portable battery power source. Battery 1 iselectrically connected to heating element 2 through relay 3. The relay 3may be a mechanical, or preferably a solid state relay. Relay 3 iscontrolled by control circuit 6 which includes microprocessor 4.Temperature sensor 5 is in thermal contact with heating element 2, andis monitored by control circuit 6. Optional ambient relative humiditysensor 7 and ambient temperature sensor 8 are also monitored by controlcircuit 6. Ready light 9 (see FIG. 4) is controlled by microprocessor 4.Power for the entire system is supplied by battery 1. The heatingelement 2 is positioned in air path 11 formed by the cylinder 12,leading to aerosol generation device 13.

FIG. 4 is an embodiment of an aerosol drug delivery device utilizing theinvention. The device 40 shown in FIG. 4 is loaded with a disposablepackage 14. To use the device 40 a patient inhales air from themouthpiece 18 through the opening 25 in the cylinder 12. The air drawnin through the opening 25 (and optionally the desiccator 24) flowsthrough the flow path 11 of the channel 12. The disposable package 14 iscomprised of a plurality of disposable containers 15. Each container 15includes a drug formulation 16 and is covered by a nozzle array orporous membrane 17. The heating element 2 is located in the flow path11. The heating element 2 is preferably positioned such that all or onlya portion of the air flowing through the path 11 will pass by theheating element 2, e.g., flow vent flaps can direct any desired portionof air past the heating element 2. The relay 3 (see FIG. 3) ispreferably closed for 30 sec or less prior to inhalation and openedafter drug delivery to conserve power.

The device 40 may include a mouth piece 18 at the end of the flow path11. The patient inhales from the mouth piece 18 which causes aninspiratory flow to be measured by flow sensor 19 within the flow pathwhich path may be, and preferably is, in a non-linear flow-pressurerelationship. This inspiratory flow causes an air flow transducer 20 togenerate a signal. This signal is conveyed to a microprocessor 4 whichis able to convert the signal from the transducer 20 in the inspiratoryflow path 11 to a flow rate. The microprocessor 4 can further integratethis continuous air flow rate signal into a representation of cumulativeinspiratory volume.

When the device is turned on by the user, the microprocessor 4 will senda signal to send power from the power source 1 (which is preferably asmall battery) to the air temperature controller 2 and will continue topreheat the temperature controller 2 until it reaches a predeterminedtemperature. The preheat temperature can be preprogrammed based on suchinformation as the particle diameter generated, the particle diameterdesired, the formulation concentration, and other parameters. Themicroprocessor 4 may also adjust the preheat temperature to optimizeeach delivery based on the ambient conditions, using information fromthe optional hygrometer/temperature sensor 7. The microprocessor 4 alsosends a signal to an actuator 22 which causes the mechanical means(e.g., the piston 23) to force drug from a container 15 of the package14 into the inspiratory flow path 11 of the device 40 where the aerosolis formed and entrained into the inhalation air and delivered into thepatient's lungs.

When the formulation 16 includes water as all or part of the carrier itmay also be desirable to include a desiccator 24 within the flow path11. The desiccator 24 is preferably located at the initial opening 25but may be located elsewhere in the flow path 11 prior to a point in theflow path when the formulation is fired into the flow path in the formof aerosol particles. By drawing air through the desiccator 24 watervapor within the air is removed in part or completely. Therefore, onlydried air is drawn into the remainder of a flow path. Since the air iscompletely dried, water carrier within the aerosol particles will morereadily evaporate. This decreases the energy needs with respect to thetemperature controller 2. The desiccator material can be any compoundwhich absorbs water vapor from air. For example, it may be a compoundselected from the group consisting of P₂O₅, Mg(ClO₄), KOH, H₂SO₄, NaOH,CaO, CaCl₂, ZnCl₂, and CaSO₄.

Device Operation

The operation of the device 40 can be understood by reference to acombination of FIGS. 3 and 4. Referring to FIG. 3 when the relay 3 isclosed the heating element 2 begins to heat. In addition to the heatingelement 2 present within the flow path 11 the flow path may also includea humidity sensor 7, temperature sensor 8 and electronic airflow sensor26. When a patient (not shown) inhales through the mouth piece 18 airflows in through the opening 25 and is sensed by the air flow sensor 26after being electronically converted by the transducer 20. The signalflows along the electrical connection 26 to the microprocessor 4. Thecombination of the control circuit 6 and the microprocessor 4 send asignal back through the connection 26 to the heating element 2 which ispowered by the battery 1. The amount of power to be supplied to theheating element 2 is also tempered, to a degree, by information receivedfrom the humidity sensor 7 and temperature sensor 8 which information isconsidered by the microprocessor 4. When the heating element 2 reachesthe correct temperature and the air flow sensor 26 determines that theinspiratory flow rate and inspiratory volume are at the desired pointthe microprocessor 4 sends a signal to the actuator 22. The actuator 22may be any type of device such as a solenoid which then moves themechanical release member 21 so that the piston 23 is released. Thepiston 23 is forced upward by a spring or other biasing means 28. Thebiasing means may be held within a grip 29 which can be easily held bythe user. Where the microprocessor 4 sends the signal through the line30 to the actuator 22 the spring is released and a container 15 iscrushed and the formulation 16 inside the container is released throughthe membrane 17.

When the container 15 is present in the drug release position below thepiston 23 the container 15 may have vibrating devices 31 and 32positioned on either side or a single device surrounding the container15. The vibrating device(s) may be actuated by the microprocessor 4sending a signal through the connection 23. Empty containers 15 areshown to the left of the drug actuation point. In a preferred embodimentof the methodology a new container and new porous membrane are used foreach drug release. By using a new porous membrane each time clogging ofthe porous membranes is avoided. Further, possible contamination of theformulation 16 present in the container 15 is avoided.

Those skilled in the art will recognize that a variety of differentcomponents could be used in place of some of the components shown withinFIGS. 3 and 4. For example, rather than including a piston biased by aspring it would be possible to utilize a rotating cam. Also, rather thanpassing the formulation through a porous membrane to generate theaerosol, an aerosol could be generated by jet nebulization, ultra-sonicnebulization, spinning disk atomization, dispersion of a dry powder, andpneumatic atomization such as by swirl atomization, or air blastatomization. Further, other components of the invention, althoughpreferred, are not required. For example, components such as thehumidity sensor 7 and temperature sensor 8 could be eliminated withoutsubstantial impairment of operability by simply adjusting the amount ofenergy supplied to the heating element 2 so as to compensate for anyhumidity or temperature which might be encountered by the user. However,such would acquire the use of unnecessary amounts of power in somesituations.

When the air temperature controller shown in FIG. 3 is activated,microprocessor 4 closes relay 3, commencing the preheat of heatingelement 2. Microprocessor 4 monitors temperature sensor 5 until heatingelement 2 reaches a temperature that is determined by ambient conditionsas measured by optional ambient relative humidity sensor 7 and/orambient temperature sensor 8, or preferably a temperature that has beenpreviously determined to be sufficient for all ambient conditions to beseen in the normal operation of the device. When this temperature isreached, the microprocessor opens relay 3 to inhibit further heating,and lights the ready light 9 to signal to the patient that the device isready for a dosing event. The microprocessor continues to monitortemperature sensor 7 and opens and closes relay 3 as required tomaintain the desired temperature until the patient inhales from thedevice.

Heating Element and Efficiency Enhancement

FIG. 5 shows an end view of a configuration of a heating element 120according to the present invention which is particularly useful when theamount of carrier to be evaporated is about 45 microliters in about aliter of air in less than about three seconds, more preferably 1 to 2seconds, most preferably about 1 second, using no more than 4 AA batterycells as the power source. The largest source of inefficiency in knownheating elements such as disclosed in U.S. Pat. No. 6,131,570, forexample, was displayed in the energy remaining in the heating element atthe end of a transfer cycle corresponding to the inhalation by apatient, during which time heat is transferred from the heating elementto the air flowing over the heating element to be mixed with theaerosol. One way of improving the heat transfer efficiency of a heatingelement during such a transfer cycle is to increase the surface area tomass ratio of the heating element. The heating element 120 is formedfrom an electrically resistive ribbon 120′ as shown in FIG. 6,preferably of nichrome, characterized by a significantly higher surfacearea/mass ratio than that of previous nichrome element embodiments, suchas 24 gauge or 28 gauge wire embodiments. The surface area/mass ratio ofribbon 120′ is preferably in the range of about 1.5 to 30 in²/g, morepreferably in the range of 3 to 20 in²/g, most preferably in the rangeof 4 to 7 in²/g. The use of ribbon is superior to simply thinning downthe cross sectional area of wire because the ribbon is more rigid thanwire having a similar thickness. Additionally, because itscross-sectional area can be changed by simply changing the ribbon width,a wide range of mass/resistance combinations are available for tuningthe heating element to have the desired heat storage and heat transfercharacteristics. Although nichrome is preferred, it is possible to useother alloys exhibiting high electrical resistivity and high resistanceto oxidation at elevated temperatures, to include alloys containingcopper, chromium, iron and/or nickel, for example.

The flat ribbon 120′ is constructed as a two bank piece 120 a, 120 b(FIG. 6), and the banks are then formed into a series of narrow channelsor grooves 121 by forming corresponding bends 122 and 124 in both banks.In other configurations the heating element may comprise a greaternumber of banks. The distance between the banks should be small toreduce preheat losses due to free convection, preferably less than 0.24inches, more preferably less than 0.16 inches, and most preferably lessthan 0.08 inches. The total element length and width are selected toexhibit the desired mass and electrical resistance. The electricalresistance of the element is preferably in the range of 0.05 to 20 ohms,more preferably 0.07 to 4 ohms, most preferably 0.1 to 2 ohms. The massof the element is preferably in the range of 0.05 to 5 grams, morepreferably in the range of 0.1 to 4 grams, most preferably in the rangeof 0.2 to 2 grams.

The width of the channels of the corrugated ribbon is small to mitigatepreheat losses due to free convection, preferably less than 0.16 inches,more preferably less than 0.11 inches, and most preferably less than0.06 inches.

The mitigation of preheat losses due to free convection results in amore uniform temperature inside the heating element and therefore in agreater insensitivity to device orientation and sensor location. Thechannels of one bank with respect to the other may be, but need not bealigned with one another, as can be seen by comparing the schematicexample showing aligned banks 102 a. 120 b in FIG. 7A with the schematicexample showing non-aligned banks 102 a, 102 b in FIG. 7B. In fact, amisalignment can be used to increase the efficiency of heating of movingair. For example, if the channels or grooves 121 defined by the firstbank 120 a are aligned with those channels or grooves 121 of the secondbank 120 b (see FIG. 7A), the air flowing out of the first bank 102 aand into the second bank 120 b would be colder at the midplanes m of thechannels than near the channel walls w (the ribbon surface). Instead,when the channel walls w of the first bank 120 a are positioned on theplanes defined by the midplanes of the channels 121 of the second bank120 b (see FIG. 7B) the air flowing into the second bank 120 b iswarmest in the midplanes m of the channels 121 of bank 120 b. Bank 120 bcan also be offset from bank 120 a at positions intermediate of thenon-offset configuration in FIG. 7A and the offset positioning shown inFIG. 7B.

The heating element may then be mounted in a channel 12, as shown inFIG. 8 with the view of channel 12 being cut away. Channel 12 may beformed from polyether ether ketone (PEEK) or other material which ispreferably also stable at elevated temperatures and relativelynon-thermally conducting. Penetrations 12 a and 12 b are formed in thechannel 12 to allow the passage of electrical contacts 12 c (see FIG. 9)which electrically connect the heating element with a power source. Thepenetrations are preferably designed such that they will secure theposition of the contacts and the element while preventing air fromleaking through them. Alternatively, the contacts may run through theair pathway without penetrating channel 12.

A shield 60 may be (and preferably is) provided around the heatingelement 120, such that it closely surrounds the heating element 120, butdoes not touch it. The distance between the element 120 and the shield60 is small to reduce preheat losses due to free convection, preferablyless than 0.25 inches, more preferably less than 0.18 inches, mostpreferably less than 0.12 inches. Shield 60 may be formed of nichromeribbon or similar material with thickness preferably in the range of0.0005 to 0.020 inches, more preferably in the range of 0.001 to 0.010inches, most preferably in the range of 0.002 to 0.005 inches, andcompletely surround the heating element on four sides and along theentire length thereof, leaving open only the ends through which air flowis channeled. The ends may be closed with shield closing elements 70 inFIG. 10, that contain open spaces to allow air to flow therethrough.Shield closing elements 70 are preferably made of wire mesh, and arethus referred to as “mesh elements”, but may be made of perforated sheetmetal or the like which allow flow therethrough, but also act as ashield and discourage convection during energy storage (e.g., during thepreheat stage) while acting as a passive element during energy release(e.g., after operation temperature has been reached and air is flowedthrough the shield closing element(s) and heating element). Shieldclosing (mesh) elements 70 are preferably close to heating element 120on both ends to reduce preheat losses due to free convection, preferablyless than 0.25 inches, more preferably less than 0.18 inches, mostpreferably less than 0.12 inches. The shield 60 may be formed to haveone or more tabs 60 a that extend to connect with the channel 12, butthis is kept to a minimum to minimize heat transfer to the channel 12.The distance between the shield 60 and the channel 12 is small to reducepreheat losses due to free convection, preferably less than 0.25 inches,more preferably less than 0.18 inches, most preferably less than 0.12inches. Heat that is normally transferred to the surroundings (in theabsence of a shield) during preheating of the heating element 120 (dueto radiation and free convection) is instead transferred to the shield60 during the preheat. Some of this heat is then recovered andtransferred to the air that flows over the shield 60 and heating element120 during an inhalation.

Meshes 70 may be formed of nichrome wire or the like, having a diameterof about 0.0005″ to about 0.0100″, more preferably about 0.0045″ toabout 0.0065″, and about 5% to 60% open area, more preferably about 10%to 50% open area, and most preferably about 20% to 40% open area. Inletplates with holes forming a similar amount of open area couldalternatively be used in place of the mesh element 70 on the inlet sideof the shield 60. Use of the shield closing elements 70 and shield 60has been shown to increase the efficiency of the heating element, mostlikely by reducing heat losses during preheat losses (i.e., preheatlosses) due to free convection and thermal radiation.

Passive elements can be introduced in the air flow path downstream fromthe heating element to lengthen the thermal time constant in moving airof the heating device.

These are typically perforated or porous, and may be made of woven wiremesh, for example, to allow the air to pass through, although otherexample geometries that may be employed include corrugated members, foamand/or wire. During the early part of the air warming period, theyabsorb heat from the moving air, while during the late part of the airwarming period they release heat into the moving air, thus lengtheningthe time constant. Passive elements may result in a heat transferinefficiency because the heat that they absorb will not entirely bereleased to the air during the air warming operation. Therefore, themasses and geometries of the passive elements must be carefully chosento create the desired effect without greatly reducing efficiency, andwill vary depending upon the effect desired.

An example of a passive heating element 174 is shown in FIG. 11. FIG. 11shows an arrangement which lengthens the time constant of the heatingdevice for better matching of the heat pulse developed thereby to theaerosol being generated. One or more passive elements 174 are situateddownstream of one or more heating elements 172 (which may be of a ribbontype 120 or other configuration as described herein) in heating device170. During the early part of the air warming period the passiveelement(s) 174 absorb(s) heat from the moving air having flowed pastheating element(s) 172 (in the direction of the arrow in FIG. 11) andwarmed thereby. During the later part of the air warming period, thepassive element(s) 174 release(s) heat into the moving air, thuslengthening the time constant in moving air of the overall heatingdevice.

Another way of increasing efficiency in a temperature controlling deviceis to apply a gold coating over the heating element and/or shield and/orshield closing element(s). The emissivity of gold is very low (i.e.,0.02) compared to materials used for making the heating element, shieldand shield closing elements. For example, the emissivity of nichrome isabout 0.8. Thus, by sputtering a very thin layer (on the order of a fewatoms thick) of gold over one or more of the previously mentionedcomponents, increases in efficiency in storing heat of about 10% havebeen achieved.

As noted above, the heating devices described above are configured to bepowered electrically, such as by batteries, so as to be portable. Forexample, to power a system including a heating device in combinationwith a delivery device, five AA-sized Nickel Metal-Hydride cells (orless, e.g., two, three, four) are connected in series to give a batteryvoltage of about 5 V. The cells each have a capacity of about 1.3 Ahr.

Energy For Evaporation

FIG. 12 is a graph which can be used in calculating the amount of energyneeded to control the diameter of delivered droplets by controlling theamount of evaporation of carrier from the aerosolized droplets. Thegraph of FIG. 12 contains two types of information, the density ofevaporated water vs. temperature and relative humidity, and the coolingof the air as the water evaporates. The four lines that show a rapidincrease with temperature portray the density of water vapor in air, at25, 50, 75, and 100% relative humidity, respectively. The 100% relativehumidity curve represents the maximum number of milligrams of water thatcan be evaporated per liter of air. The diagonal lines show thetemperature change of the air as the water droplets evaporate (hereaftercalled the air mass trajectory curves). As the evaporation proceeds, thedensity and temperature will change by moving parallel to these curves.To calculate these curves, air density of 1.185 grams/liter, airspecific heat of 0.2401 calories/gram, and water latent heat ofvaporization of 0.583 cal/mg were assumed. It is also assumed that theevaporation process is adiabatic, i.e. there is no heat removed from orsupplied to the air from other sources such as the walls of the device.These values imply that a liter of air will cool 2 degrees Celsius forevery milligram of water evaporated, i.e. evaporating 10 micro-literswill cool a liter of air 20 degrees Celsius.

FIG. 12 can be used to calculate the amount of preheating needed toevaporate all or substantially all of the carrier in the aerosolparticles. As an example, assume the initial ambient conditions are 25°C. and 50% relative h_(um)idity. Further, assume that one wants toevaporate 10 μl (10 mgs) of water from an aqueous drug solution.Finally, assume the final relative humidity is 75%. Under theseconditions the aqueous carrier would not in general evaporatecompletely. More specifically, the final particles would containapproximately equal amounts of drug and water. To calculate the amountof energy to add for this delivery maneuver, refer to FIG. 12. Locatethe point corresponding to 25 C and 50% relative humidity. Move up by 10milligrams, the amount of water to be evaporated. Now move to the rightuntil the 75% RH curve is crossed. This occurs at about 29 C. Theseconditions (75% RH and 29 C) represent the condition of the air asdelivered to the patient. However, still more energy must be added tomake up for the cooling of the air as the water evaporates. To calculatethis amount of heat, move parallel to the air mass trajectory curves(downward and to the right) until the initial ambient water vapordensity is reached, at approximately 47 C. Thus, sufficient heat to warmthe air by 22 C must be added to achieve near complete evaporation.

FIG. 13 includes similar information with respect to ethanol which canbe used in a similar manner. A preferred embodiment of the inventioncomprises a microprocessor programmed to calculate the amount of energyneeded for the formulation being aerosolized with consideration to thesurrounding temperature and humidity being accounted for. In a preferredembodiment, containers of formulation loaded into the device are labeledin a manner which is read by the device which then considers thediameter of the formulation dose to be aerosolized and the amount ofliquid to be evaporated.

The evaporation and growth rates of aqueous droplets is a function oftheir initial diameter, the amount of drug dissolved therein(concentration) and the ambient relative humidity and temperature. Thedetermining factor is whether the water vapor concentration at thesurface of the droplet is higher or lower than that of the surroundingair. Because the relative humidity at the surface of a particle (i.e.droplet of aerosolized formulation) is close to 100% for mostformulations of interest, evaporation will occur under most ambientconditions until the rising humidity of the air equals the decreasinghumidity at the surface of the droplet. A five micron droplet isexpected to evaporate to a 1 micron dry particle in 0% humidity in lessthan 20 ms.

When administering drug using the inhalation device of the presentinvention, the entire dosing event can involve the administration ofanywhere from 10 μl to 1,000 ml of drug formulation, but more preferablyinvolves the administration of approximately 15 μl to 200 μl of drugformulation. Very small amounts of drug (e.g., nanogram or largeramounts) may be dissolved or dispersed within a pharmaceuticallyacceptable, liquid, excipient material to provide a liquid, flowableformulation which can be readily aerosolized. The container will includethe formulation having drug therein in an amount of about 10 μg to 300mg, more preferably about 1 mg. The large variation in the amounts whichmight be delivered are due to different drug potencies and solubilitiesand different delivery efficiencies for different devices, formulationsand patients.

System Specification Envelope

The following information is provided to specify an approximate envelopefor the design of various features of a temperature controlling systemaccording to the present invention.

A. Batteries

Chemistry: Nickel Cadmium, Nickel Metal-Hydride, Lithium-Ion,Lithium-Metal, Lithium Polymer

Voltage: 1 Volt to 20 Volt

Internal Impedance: less than 0.1Ω per cell

Number of cells: 1 to 10

B. Control Relay

Type: Solid State, Mechanical, Transistor

C. Temperature Sensors

Types: Resistance, Thermocouple, Diode

The following example is put forth so as to provide those of ordinaryskill in the art with a complete disclosure and description of how tomake and use various constricts and perform the various methods of thepresent invention and are not intended to limit the scope of what theinventors regard as their invention nor are they intended to representor imply that the embodiments described below are all on the onlyembodiments constructed or tested. Efforts have been made to ensureaccuracy with respect to numbers used (e.g., amounts, concentrations,particular components, etc.) But some deviations should be accountedfor.

EXAMPLE

One example of a heating device according to the present invention ischaracterized in Table 3 above and employed a ribbon type heatingelement as described above, with the heating device being powered by 4AA NiMH battery cells arranged in series. The ribbon was made from anichrome alloy (80% nickel, 20% chromium), had a mass of about 1.2 g., asurface area of about 39 cm² and a thickness of about 0.0031 inches, andwas formed to have two banks like that described with regard to FIG. 6above. The channel or gap width between folds of the heating element wasabout 0.048 inches and the distance between banks (as described withregard to FIGS. 6 and 8 above) was about 0.060 inches. The heatingelement exhibited an electrical resistance of about 0.8 ohms and a heatcapacity of about 0.5 J/° C. A shield 60 (as shown and described withrespect to FIG. 9) surrounded the ribbon element and had a mass of about0.65 grams and a thickness of about 0.0031 inches. The distance betweenthe shield 60 and the ribbon element was about 0.055 to 0.110 inches onaverage. A shield closing element 70 was fitted in each open end ofshield 60 and each comprised a mesh element having about 30% open areaand a mass of about 0.25 grams. The distance between the shield closingelements or mesh elements and the ribbon element was about 0.065 inchesfor each. The distance between the shield 60 and the channel 12 wasabout 0.050 to 0.075 inches. The thermal time constant in still air ofthis heating device was greater than about 40 seconds The thermal timeconstant in moving air of this heating device was measured to be about3.5 seconds at an air flow rate of about 45 l/min, which was an air flowrate designed to model an inspiratory flow rate of a patient.

The invention as shown and described is considered to be the one of themost practical and preferred embodiments. It is recognized, however,that the departures may be made therefrom which are within the scope ofthe invention and that obvious modifications will occur to one skilledin the art upon reading this disclosure.

1.-41. (canceled)
 42. An electrically resistive ribbon for use in ahand-held, portable air temperature controlling device, said ribbonhaving a mass of about 0.05 to 5.0 grams and a surface area of about 25to 60 cm².
 43. The electrically resistive ribbon of claim 42, whereinsaid ribbon is corrugated to form gaps to channel air therethrough. 44.The electrically resistive ribbon of claim 42, wherein said resistiveribbon is constructed of two banks and each said bank is configured intoa series of narrow channels.
 45. The electrically resistive ribbon ofclaim 42, wherein said ribbon has a mass of about 0.1 to 4.0 grams and asurface area of about 30 to 55 cm².
 46. The electrically resistiveribbon of claim 45, wherein said ribbon has a mass of about 0.2 to 2.0grams and a surface area of about 35 to 45 cm².
 47. The electricallyresistive ribbon of claim 46, wherein said ribbon has a mass of about1.25 grams and a surface area of about 39 cm².
 48. A hand-held,portable, air temperature controlling device, comprising: a selfcontained power source; and a heating element having a thermal timeconstant in moving air of less than 5 seconds.
 49. The air temperaturecontrolling device of claim 48, wherein the thermal time constraint ismoving air is about 3.5 seconds.
 50. The air temperature controllingdevice of claim 48, wherein the heating element is an electricallyresistive ribbon having a mass of about 0.05 to 5.0 grams and a surfacearea of about 25 to 60 cm².
 51. The air temperature controlling deviceof claim 50, wherein said ribbon is corrugated to form gaps to channelair therethrough.
 52. The air temperature controlling device of claim50, wherein said resistive ribbon is constructed of two banks and eachsaid bank is configured into a series of narrow channels.
 53. The airtemperature controlling device of claim 50, wherein said ribbon has amass of about 0.1 to 4.0 grams and a surface area of about 30 to 55 cm².54. The air temperature controlling device of claim 50, wherein saidribbon has a mass of about 0.2 to 2.0 grams and a surface area of about35 to 45 cm².
 55. The air temperature controlling device of claim 50,wherein said ribbon has a mass of about 1.25 grams and a surface area ofabout 39 cm².
 56. The air temperature controlling device of claim 48,wherein the self contained energy source is chosen from an electricalcell and an electrical battery.
 57. The air temperature controllingdevice of claim 56, wherein the self contained energy source compriseslithium.
 58. The air temperature controlling device of claim 48, whereinthe self contained energy source comprises lithium polymer.
 59. The airtemperature controlling device of claim 48, wherein the heating elementcomprises a metal chosen from nickel, iron, chromium and copper.
 60. Theair temperature controlling device of claim 48, wherein the heatingelement comprises iron.
 61. The air temperature controlling device ofclaim 48, wherein the heating element comprises nichrome ribbon.
 62. Theair temperature controlling device of claim 48, wherein the mass of theheating element is about 0.05 to 5.0 grams.
 63. The air temperaturecontrolling device of claim 48, wherein the mass of the heating elementis 0.1 to 4 grams.
 64. The air temperature controlling device of claim48, wherein the mass of the heating element is about 0.2 to 2.0 grams.65. The air temperature controlling device of claim 55, wherein thethickness of the ribbon is 0.0005 to 0.010 inches.
 66. The airtemperature controlling device of claim 55, wherein the thickness of theribbon is 0.001-0.006 inches.
 67. The air temperature controlling deviceof claim 55, wherein the resistance of the heating element is 0.5-3.0ohms.
 68. The air temperature controlling unit of claim 48, whereinenergy in the range of about 50 to 400 joules is supplied to the air inabout 0.5 to 4.0 seconds.
 69. The air temperature controlling unit ofclaim 48, wherein the energy is supplied to the air in about 1-2 second.70. The air temperature controlling unit of claim 48, wherein the energyis about 250 joules.
 71. A method of heating air surrounding an aerosol,comprising: preheating a heating element of an air temperaturecontrolling device until the heating element is determined to reach apreviously determined temperature; wherein the air temperaturecontrolling device comprises a self contained power source; and aheating element having a thermal time constant in moving air of lessthan 5 seconds.
 72. The method of claim 71, wherein air is driven byinhalation of a user.
 73. The method of claim 71, wherein the aerosolcomprises a drug formulation.
 74. The method of claim 73, wherein thedrug formulation is a liquid, flowable formulation.
 75. The method ofclaim 73, wherein the drug formulation comprises a peptide drug.
 76. Themethod of claim 75, wherein the peptide drug is chosen from insulin andan insulin analog.
 77. The method of claim 73, wherein the aerosolformed by formulation comprising the carrier and drug that is forcedthrough pores having a diameter of 0.25 to 3.0 microns.
 78. The methodof claim 71, wherein the temperature of the heating element isdetermined with a microprocessor.
 79. The method of claim 71, whereinthe temperature of the heating element is determined by a measure ofresistance of an electrical component.